Process of making compound metal objects.



J. I'. MONNOT.

PRoGEss 0E MAKING GOMPOUND METAL OBJECTS.

APPLICATION FILED JULY 16, 1908.

927,062. Patented July e, 1909.

TD /////A,///// Inventor:

UNITED sTA'izs PATmsrr4 OFFICE.

JOHN F. MONNOT, OF NEW YORK, N. Y., ASSIGNOR TO DUPLEX MTALS COMPANY, OF N EW YORK, N. Y., A CORPORATION OF NEW YORK.`

PBCO-E88 OFIAI'DG GOHPOUND METAL OBJECTS.

Specification o! Letters Patent.

Application led July 16, 1900. Serial No. 448,797.

Patented July 6, 1909.

To all whom 'it may concern:

Be it known that I, JOHN F. MoNNoT, 4a citizen of the United States, residing at New York, in the county of New York and State of New York, have invented certain new and useful Processes of Making Compound Metal Obj ects, of which the following is a specification.

My inventionrelates to proc of making` compound metal objects and particularly to processes of making objects comprising a core of non-ferrous metal and a coating of ferrous metal, such as steel, such core and coating being weld united.

In another application for Letters Patent, Ser. No. 443,796, filed Jul 16, 1908, I have illustrated and described ectrical conductor wire comprising a core of high-conductivity metal, such as copper, and a shell of harder or stronger metal, such as steel, Weldunited thereto. The resent a plication covers a process of pro using suc article and other similar articles.

In the accompanying drawings I illustrate the method of carrying out my said process and apparatus convenient for use in carrying out the same. 4

In said drawings: Figure 1 shows a central vertical section of a mold, pouring funnel and aningot therein formed as' hereinafter described. Fig. 2 shows a transverse section of said mold on the line z--x of Fig. 1 Fig. 3 shows a transverse section of a completed ingot. Fig. 4 shows on a smaller scale, a

transverse section of a mold and contents, such as shown in Fig. 1, but including a core by means of which hollow ingots may be produced, and Fig. 5 shows a transverse section of a completed hollow ingot. 6' shows a top 'view of a mold adapted for formiing rectangular ingots comprisln lamina of v ferrous and non-ferrous metals. ig. 7 shows i a vertical section of such mold and of the inf-f got within it, and Fig. 8 shows a transverse section of a completed ingot.

Referring first to Figs. 1 and 2, `1 -designates a circular two-part mold provided heat.

with cooling means 2, which in the instance -shown is a jacket through which cooling,r

water, oil, etc., is circulated; or compressed air or other suitable as may be expanded in th'e jacket s ace for t e purpose of absorbing In t `c construction shown this mold is assumed to be of metal, irony molds being permissible in casting copper and like metals against a steel shell or between a steel shell and the sides of the mold, according to the method referred to. But, in lieu of circulation of the cooling fluid through a cooling jacket, as shown, water or other cooling fluid may be played against the outside of the mold, or a mold of very thick metal will, in many cases, iii-itself have sufficient heatstorage capacity for the purpose desired.

Instead of employing la metal mold, a mold of refractory material, for example, a mold of homogenized carbon, such as illustrated and described in m' a plication Sr. No. 430,097 may be use( l) have indicated a sectional mold` instead of a one piece mold such as commonly used in castmg ingots,

simply because `it is desirable in many cases that the ingot produced shall have no draft vertically; otherwise a one iecemold would be used. The sectional rno d comprises suitable means, as for example, bands 3 and wedges 4, to prevent separation of the sections of the mold during the casting, and until the cast metal has solidified.

5 designates a shell or 'tube of steel or iron to form the steel coating of the resulting article, its thickness being properly proportioned, with reference to the diameter of the ingot, so that this steel shell when extended or drawn down to final size in forming a finished article, will have the desired thickness. This steel shell, before it is placed in the inot mold, may have beenathinly coat-ed by ippin g it for a brief interval in su ermolten copper or other suitable superino ten coating metal, according to the method set forth in my Patent No. 853,716, in which' patent I have set forth a process of producing clad metals based on the fact that while copper and like metals do not form any weld-limon when contacted at ordinary casting tcmperatures with a clean steel surface, yet such a weld union is formed when the copper or i like metal with which the steel is contacted is heated to a considerably higher temperature, termed by me in'sald patent, for thc sake of a name, the su' ermolten temperature". And as set forti in said patent, a steel object immersed momentarihT in a bath of such supermolten unlike metaland then withdrawn under conditions precluding oxidation, will bcfound covered with a thin Welded-on, coating. of metal of the' supermolten bath, and with this coating copper andmany other metals when cast thoremetal.

Vthe above methods, the co against at ordinarycasting temperatures .or slightly higher tem eratures,V will unlte readilv and mseparab y.. Or, the steel shell white heat before it is placedin the mold so that the molten metal cast within or within and around` said shell will be raised, in the immediate vicinity of said shell, to the supermolten condition. Or, as an alternative to er or like metal may be castwithin, or w1t 'n and around,

Vsuch shell, while in the supermolten condition. w I

6 designates a suitable pouring tile lor fun nel, which may be of refractory material, such as fire clay, or carbon, or may be of metal. In the particular instance shown the shell 5 is of somewhat smaller diameter than the interior diameter of the mold, in order that molten metal'may be cast without as well as within said shell and therefore the pouring tile 6 is provided not only with a central space 7 for the lintroduction of the molten metal for the core, but also with side spaces 8 for the introduction between the s 1ell 5 and the Inoldfof molten coating The metal l or within and around the 'shell5, is preferably cast through a deep layer' of molten wiping material 9, ac-

cording to the methods set forth in m application Sr.` No. 391,674 and my app ication Ser. No. 443,298, filed July 13,1908. Such molten wiping material removes oxid impurities and occluded'and entrained gases and insures a particularly dense,l tough and homogeneous casting, free from blow holes,t

blebs, etc. also if this wiping material contains a considerable proportion of oXid-dissolving ingredient the mold need be only` partly filled with this wiping material rior to the introduction of the molten meta the molten metal flowin down through this wiping material as ,it iscast and so displacing upward. the wiping material, which is of less specific gravity, said wiping material as it rises, progressively yfreeing'tlie surface of the shell 5 and, when Ametal is cast between said shell and the sides,- of the mold, also freeing the mold walls, of oXid or like impurities, absorbed gases, etc. A suitable wiping material is borax or a mixture of boraXand sodium or potassium silicate to which a little fluor spar may be added. The proportions 'of .the ingredients of the wiping material may be varied as re uired to produce a material which will be (flreely liquid at the temperature at which the molten metal is cast.

This 1b .iiiping material may, if desired, be l placedfin, the mold solid, since the first of the moltengmetal introduced into the mold will melt it; or if theshell 5 be placed at a white heat in the mold, the heat from this shell will suflice in eneral to melt solid wiping material lacet? within the mold.

T e shell 5 and the wiping material having been placed in the moldas specified, molten copper or other metal to form the core and, if an outer coating is desired, to form such outer coating, is poured into the mold and in assing through the molten wiping material 1s cleansed as above described, and caused to contact with the surface of the shell 5, and is permitted to solidify against such surface, thereby weldin g to said surface. Commonly the molten metal will be cast in such quantities as not only to completely fill the mold but also to rise somewhat into the passage or passages of the pouring funnel 6, and owing to the covering of molten wiping material, which material is of low heat conduct capacity, and to the refractory nature of funnel 6 when said funnel is of carbon, clay etc., there will be a head of molten metal within this funnel which will be relatively slow to solidify, and so will fill in an spaces left by contraction of the metal belbWL the hydrostatic pressure due to this additional height of molten metal and of thewiping material above it further tending to insure'a tough dense cast metal free from blow holes and the like. If desired, the molten metal cast between the shell 5 andthe walls of the mold,

ymay be cast after the casting of the metal within said shell, after such metal within the shell has begun to solidify, the shrinkage of the metal so cast outside of the shell tending to force the contraction of the shell to keep pace With the contraction of the metal cast within it, and such contraction may be hastened by the circulation of cooling fluid through the jacket 2, the rapid cooling so produced also improving the quality of the cast metal, if it be cop er or like metal, and preventing any attacli) of the metal ofthemold, if the mold be of metal, by the cast metal, if the latter be cast at supermolten temperature; and this ra id cooling further tends to prevent attack o' the metal of the shell by the cast metal, if the latter be cast at supermolten temperature, to such extent as to contaminate the cast metal. The ingot so produced may be worked in the ordinarv manner, either immediately after solidification, or after submission to -a soaking heat-- ing, and may be rolled and drawn down to final size and shape in the ordinary manner.

Fig. 3 shows a transverse section of a three-layer ingot as removed from the mold, and also in substance shows a cross section of a round object rolled or drawn down from rio an ingot such as described, since the metals extend substantially in the same proportion,

both, adapted for forming a Weld union, and permitting the molten metal so cast to solidify as soon as such Weld union is effected.

6. A process of producing compound metal objects comprising unlike metals weld united, which comprises casting molten bodies of copper into contact with opposite surfaces of a separator of steel under conditions of temperature of molten metal, or separator, or both, adapted for forming a weld union, progressively cleaning one or both said surfaces by the action thereon of a deep layer of molten ilux containing oXid-dissolVing-material and permitting the molten metal so cast to solidify.

7. A process of producing compound metal objects comprising a steel annulus and a layer of copper within said annulus and weldunited thereto, which comprises casting molten copper within a tube or shell of steel and in contact with the inner surface thereof, under conditions of temperature of the molten metal, or tube, or both, adapted for forming a Weld union, and permitting the molten metal so cast to solidify as soon as such weld union is eected.

8. A process of producin compound metalA objectsv comprising a stee annulus and a f ayer of copper within said'annulus and weldunited thereto, which comprises casting molten copper within a tube or shell of steel and in contact with the inner surface thereof, under conditions of temperature of the molten metal, or tube, or both, adapted for forming a weld union, progressively cleaning one or both said surfaces by the action thereon of a deep layer of molten :liux containing oxiddissolving material and permitting the molten metal so cast to solidify.

In testimonylwhereof I affix my signature, in the presenceff two witnesses.

v Witnesses:

I-I. M. MARBLE,

FRANK E. RAFFMAN.A

JOHN F. MONNOT. i 

